POLYPLUMB POLYPLUMB POLYPLUMB

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1 POLYPLUMB POLYPLUMB POLYPLUMB DESIGN INSTALLATION Redefining Heating Systems PRODUCT SELECTION Floor Heating Solutions

2 INDEX Introduction 03 Benefits of Polyplumb Floor Heating Choice of Floor Coverings Polyplumb System Specifying Polyplumb Floor Heating 10 Floor Heating Systems 11 Solid Floor Systems Suspended Floor Systems Floating Floor Systems Overlay Floor Systems Manifolds 26 Water Temperature Controls 27 Room Temperature Controls Connections to Heating System 30 Heat Output Table 31 Jointing and De-Mounting Floor Heating Commissioning Procedure House Pack Quick Selector Guide and Polyplumb Service Selection Process Product Selection Form 41 Design Service 42 Design Enquiry Form 43 STANDARDS Manufacturing Quality Assurance In accordance with BS EN ISO 9001:2000 (BSI registered firm FM00318 Certificate FM00318). Installation Standard - to follow the recommendations of BS PART Plastic pipework (Thermoplastic Materials). SYSTEM APPROVALS British Standard Class S rated to BS7291 Part 1 and Kitemark Licence Number to BS7291 Part 2. WRAS Listed in the WRAS Water Fittings and Materials Directory. KIWA/ KOMO Certificate numbers K14341, and BBA Polyplumb polybutylene barrier pipe, fittings, accessories and floor central heating systems are covered by BBA Certificate No 00/3699. British Gas - has accepted the Polypipe Polyplumb Class S polybutylene pipe system as being acceptable for open vented and sealed central heating systems and is eligible for acceptance onto Three Star Central Heating System Cover. P.B.P.S.A. Polypipe Building Products Ltd is a member of the Polybutylene Piping Systems Association, which is a recognised association of companies whose aim is to promote the features, benefits and best practice installation techniques of polybutylene pipe systems, as well as providing a wide range of technical information and support. 2

3 INTRODUCTION Polypipe, one of Europe's largest manufacturers of specialist plastic plumbing products, has developed the Polyplumb range of floor heating systems. Polypipe are also members of the Underfloor Heating Manufacturers' Association (UHMA), who set and enforce standards for materials, design and installation of floor heating systems. Our products are also safer to install, as jointing does not require the use of solvents, solder or naked flames. The systems offer other benefits to installers and users, including: Resistance to impact damage and freezing No scale build up or corrosion Completely lead free Minimal system creaking or water hammer Electrically non-conductive Polyplumb floor heating systems have been designed with specifiers, installers and users in mind. Our systems combine ease of installation with reliable long-term performance, and we hold a range of stock ready for prompt dispatch. The Polyplumb range of products includes traditional under floor central heating, perfect for renovation and new build properties; and the unique Overlay system, which is an ideal solution for single room refurbishments. Whatever job you are undertaking, Polypipe has the product to suit you. Polyplumb is a recognised and respected brand, and is well established as the system of choice by many installers for domestic homes. All our floor heating solutions are a complete system, and require no additional components for installation. Polyplumb floor heating solutions are rigorously tested, and comply with (or exceed) all relevant UK standards. We use an integrated flexible plumbing system, incorporating polybutylene pipes and a range of push-fit fittings. The systems are also designed for use with copper pipes, allowing the integration of rigid pipes when necessary. 50 year guarantee Polyplumb floor heating products, excluding manifolds and control products, are covered by a 50 year guarantee*, which protects against defects in materials or manufacture of the heating system from date of purchase. This guarantee only applies if the system is installed in accordance with the manufacturers recommendations (see pages 12-25), and is used in a normal domestic operation. This document should be read in conjunction with all other documentation supplied with Polyplumb products. If you have any queries please contact our Technical Department on * Full terms and conditions are available at 3

4 BENEFITS OF POLYPLUMB FLOOR HEATING Heating technology has advanced considerably, and floor heating is now much more affordable and an efficient way of heating homes. Installing floor heating opens up a whole range of possibilities for homeowners, revolutionising interior design and creating a comfortable, gentle and even heat. Easy installation All Polyplumb floor heating systems can be installed quickly and easily, up to 20% quicker than radiators. Our range of innovative products allow systems to be installed with minimal disruption to existing heating and electrical supplies, and are compatible with standard central heating boilers. Polyplumb systems are installed in one stage, meaning there is no costly and time consuming second fix stages. The floor heating components are much easier to manoeuvre on site than large, bulky radiators; they can be carried by one man and are less likely to get damaged. There is also very little theft value during installation, as opposed to expensive radiators that may have to be stored for periods of time. Full installation instructions for Polyplumb floor heating systems can be found on pages Alternatively, there is a network of Polyplumb Registered Installers across the country who can ensure your system is fitted correctly. To locate your nearest heating specialist visit Maintenance free As well as being virtually maintenance free, Polyplumb systems are covered by the Polypipe 50 year guarantee (full details can be found at There are no joints in pipework within the flooring, significantly reducing the possibility of leaks. Polyplumb floor heating products are subject to rigorous testing and all manufacturing processes are in accordance with BS EN ISO Floor heating also eliminates the general need for maintenance and decoration of radiators, eg removing radiators to paint the walls. Easy to control Polypipe manufacture a range of water and room temperature control solutions, allowing you to source a complete, integrated system from a single supplier. The range includes a number of control products, with options to suit a variety of lifestyle patterns, and the abilities to control different rooms independently. Full details of Polyplumb control products can be found on pages Flexible approach Polyplumb floor heating systems use the flexibility of polybutylene pipe to provide a solution for all house and room types. We also have a range of unique and innovative products, including the zonal regulation unit (ZRU) and electric heat unit (EHU), which are excellent enablers and allow floor heating to be incorporated into single rooms or refurbishment projects with minimal disruption to existing heating and electrical supplies. For more information on our water temperature control products see page 27. Easy to install 4

5 Excellent service At Polypipe we understand that selecting the right solution for each application involves detailed consideration. This is why we offer extensive customer service support, including free system design and full technical support if any problems do arise. We want to ensure your system runs smoothly from the beginning and our technical support staff can assist you with any questions you might have. During installation we offer: Pre-project training at one of our training centre Pre-project training by distance learning On-site assistance We also provide an extensive back up service: Technical representation available to discuss systems in general and particular projects ufch.com Technical CD Specialist technical hotline on Design freedom Polyplumb floor heating eliminates the need for unsightly radiators, and offers the freedom to design rooms in imaginative and creative ways. This provides more useable wall space, and is ideal for rooms where there is already limited wall space, eg loft conversions, conservatories and bathrooms, allowing better utilisation of the areas usually restricted by radiators. Comfortable warmth The environment created by floor heating is different to that produced by radiators. Floor heating systems emit gentle radiant warmth across the entire floor surface, ensuring the room is heated evenly, eliminating draughts and cold spots, and producing a warm, comfortable atmosphere. It creates a warm zone about two metres from the floor level, making your feet a few degrees warmer than your head - ideal comfort conditions. Energy efficient Floor heating systems can be more economical to run than a radiator based system. As they demand a low temperature rise output from the boiler, they are ideally suited to achieving maximum economy from a condensing boiler or heat pump. However, they are just as efficient with higher temperature heat sources, eg solar and solid fuel, where the correct water temperature can be set at the point of distribution. Provokes a warm, comfortable environment Clean & safe Securing heating in the floor prevents any potential hazards from radiators - such as sharp, protruding edges and extremely hot surfaces. Contact with radiators at their normal operating temperatures, which can be up to 80ºC, can cause deep skin burns within minutes. Floor heating is also much cleaner than radiator systems. It reduces the air circulation within the room, minimising airborne dust particles, and does not cause dirty walls, a common problem with radiators. Range of solutions Whatever type of project you're working on, from large new build developments to individual self-build projects, or whole house refurbishments to single room DIY projects, there is a Polyplumb floor heating product for you. Our range of products can also accommodate you whatever stage of the building process you're at, even allowing you to install floor heating into existing rooms with our unique Overlay system. For further details on our products see page 11. 5

6 CHOICE OF FLOOR COVERINGS Floor heating systems will work efficiently under any floor covering, as long as it is well insulated underneath. However, each covering has different thermal conduction properties, and harder surfaces offer better conductivity, and, therefore, better heat output rates. The following notes provide some guidance on each type of covering. Stone and ceramic tiles, marble or flagstones Suitable for all Polyplumb floor systems - These types of floor finishes are usually cold underfoot. However, with floor heating they are transformed into warm comfortable surfaces. Each of these finishes is essentially brittle and it is imperative that the design of the supporting floor structure is stable and rigid to prevent cracking. It is recommended that flexible adhesives and grout be used. Carpets and underlays Suitable for all Polyplumb floor systems - The nature and thickness of the carpet underlay is fundamental in determining good heat transfer. Most underlays are sponge types that have waffle pattern moulded into their underside, and allow good heat transfer. The carpet underlays to be avoided are those such as felt and rubber crumb type. If these are used, they can seriously reduce the effectiveness of a floor heating system, as they insulate the floor surface and prevent heat transfer. The TOG value of carpets and underlays should be available from the respective manufacturer. The maximum TOG value of underlay should be approximately 0 5. The maximum TOG value of carpet should be approximately 1 0 to 1 5. Ceramic tiles Carpet 6

7 Laminate Suitable for all Polyplumb floor systems - Laminate flooring should be laid on roll type floor levelling, rather than the rigid panel type. Movement that occurs must be accommodated by an expansion gap around the floor deck. Timber Suitable for Polyplumb solid floor and suspended floor systems - Concerns regarding the effect of heat on a timber floor are misplaced, and the more important issue is the floor moisture content. Timber floors should be laid at a moisture content of 10-11%, which when heated will reduce to 8-9%, and cause a very small amount of shrinkage. The floor will re-absorb some moisture when the heating is not operating and the moisture content will increase to 12-13%. Further details on installing timber floors over floor heating systems can be found on page 15. Vinyl Vinyl Suitable for all Polyplumb floor systems - sheet vinyl is sensitive to long term exposure to heat. There are two categories of vinyl; one is limited to constant temperatures of around 26 C and the other to 30 C. Check the floor surface temperature for compatibility with vinyl flooring. If unsure contact the Polyplumb hotline or the vinyl floor manufacturer. Timber 7

8 POLYPLUMB SYSTEM The Polyplumb system is suitable for use in hot and cold water supply and both radiator and floor central heating systems. The polybutelene pipe provides flexibility & freedom when designing pipe layouts. Strength The system is suitable for use in working applications up to 12 bar / 20 C (6 bar / 90 C). Pipes are suitable for bending to a radius of 12 x diameter when unsupported or 8 x diameter when supported. Connections and fittings are tested to BS 7291: Class S for thermal cycling test, long term pressure tests, rapid pressure test and pull-out strength. System malfunction temperature Polyplumb pipes and fittings are tested to BS7291: Parts 1 and 2, which incorporates a pressurised thermal cycling test and a test regime at temperatures of 114 C and 3 5 bar pressure for 1,000 cycles at a duration of 30 minutes per cycle. See British Standards web site for further details. Gases The Polyplumb system is not suitable for the transportation of gases. Standard Polyplumb pipe is oxygen permeable and is suitable for all domestic water and heating installations. Polypipe recommends that corrosion inhibitors are introduced to, and maintained in, all heating systems, whether they use standard or barrier pipe. Due to the long pipe runs used in floor central heating systems we recommend barrier pipe is used throughout UFCH applications to minimise the potential for oxygen ingress into the system. Water The polybutylene material used in Polyplumb pipes and fittings is WRC / WRAS approved. It is resistant to the build-up of scale. Short term chlorination for disinfection of supply pipe work and normal levels of chlorine in UK domestic water supplies will not have an adverse effect on Polyplumb. Polyplumb is not suitable, however, for systems that carry a high concentration of chlorine, eg supplies to swimming pools etc. Light Polyplumb pipe and fittings should be protected from UV light. Standard decorating paints form adequate protection. Polyplumb pipe insulation forms adequate protection for external use. Polyplumb is delivered in light protective packaging. Thermal It s co-efficient of thermal expansion is 1.3 x 10-4 m/mºc. It accommodates expansion by its modulas of elasticity. Acoustic The Polyplumb system gives better performance than rigid pipe systems in terms of low noise transmission and low water hammer effect. 8

9 Electrical As Polyplumb pipe does not conduct electricity, installations generally require less equipotential bonding than metal systems. Both the IEE and the IoP give guidance on the earth bonding requirements of plastic pipe systems. Where Polyplumb breaks the continuity of existing metal pipe, which may be used for earthing or bonding, this continuity should be reinstated by affixing permanent earth clips and a section of earth cable between the ends of the copper pipe. Side-effects Polypipe believes there to be no side-effects from handling or using Polyplumb. Compatibility The Polyplumb system connects to rigid pipe systems. Polyplumb is compatible with all recommended inhibitors. For details of compatibility with specific building materials, eg filler foam, wood worm treatments, please consult the Polyplumb hotline on Polyplumb pipes and fittings can be painted using emulsion or undercoat and gloss. Cellulose based paints, strippers or thinners must not be used. Durability Polyplumb floor heating products, excluding manifolds and control products, are guaranteed for 50 years against defects in materials or manufacture from the date of purchase (exclusions apply). See page 3 for details. Maintenance Polyplumb systems require no maintenance, other than checks on inhibitor level in heating systems. 9

10 SPECIFYING POLYPLUMB FLOOR HEATING Polyplumb have made choosing and ordering materials for either single room or whole house projects quick and simple. The selection process allows customers to select the appropriate pack in three easy steps. Selection process Simply decide whether the project is a single room, a whole house solution or requires our bespoke design service, and then follow the detailed guide on pages All packs have a single order code and include all the necessary flooring and control materials. Try the process out for yourself and see how easy it is to choose the right floor heating product for your project. Polyplumb Registered Installer Network All Polyplumb floor heating solutions can be installed quickly and easily, and the unique Overlay system can be fitted by anyone with an understanding of DIY and plumbing. If you are looking to install floor heating yourself, then detailed installation instructions can be found on pages Alternatively, there is a network of Polyplumb Registered Installers across the country who can ensure your system is fitted according to the manufacturer s recommendations. All installers accepted onto the scheme go through a selection and certification process to ensure their installations are of an excellent standard. For details of your local floor heating specialists use the Find an Installer section on We are continually looking for new installers nationwide who would like to become part of the Registered Installer network. This exclusive group of floor heating installers will receive a priority service from Polypipe and genuine customer leads from Once you become a registered installer your personal web profile page will appear on the site, including full contact details and logo. You will also be entitled to order free Polyplumb sales support materials to help you provide excellent customer service to your customers and generate leads, including consumer brochures, product guides, van stickers and key rings. Joining this network is easy. We simply require two references from recent floor heating customers. If you require any further information on the Registered Installer Network please visit or call Online assistance Polypipe have designed a comprehensive website, to provide you with online help both before and during any installation. The site includes information on the benefits of floor heating, detailed explanations on the full range of Polyplumb, product applications and case studies; enabling you to explain the full potential of Polyplumb floor heating to potential customers. There are sections dedicated to installers and specifiers, with full installation instructions and downloadable brochures. The site also has the facility to search for your nearest Polyplumb merchant, along with an interactive product selector. Now there s no reason not to specify Polyplumb floor heating see for yourself how quick and simple it is at 10

11 FLOOR HEATING SYSTEMS Solid floor Polyplumb floor heating can be permanently built into solid concrete or screeded floors. As required by current Building Regulations, insulation is built into the floor directly beneath the unique Polyplumb floor panel. The heating pipe is simply slotted in and then permanently covered by the screed. Suitable for all floor coverings. Solid floor systems can incorporate 15mm or 18mm pipe. Suspended floor For installations in suspended floors, Polyplumb floor heating uses either double or single heat spreader plates. Alternatively, pipes can be laid on top of insulation between joists. Standard tongue and groove floorboard is laid above the system. Suspended double heat spreader plate systems use 15mm pipe. Single heat spreader plate and pipe only systems can use 15mm or 18mm pipe. Floating floor When installing in floating floors, Polyplumb pipe is simply pressed in to the preformed heat spreader plate, which sits in grooves within the floating floor insulation panel. The floating floor system is then covered with 18mm chipboard sheeting. Suitable for all floor covering. Floating floor systems can incorporate 15mm or 18mm pipe. Overlay Overlay allows floor heating to be installed into existing spaces quickly, easily and practically. The unique system is a patented low profile panel, which is laid over existing solid or timber floors. Tiles and laminate can be laid directly onto the system. Carpet and vinyl require a capping layer of 4-6mm plywood. Overlay is perfect for kitchens, bathrooms or conservatories, where minimal wall space is available and total design freedom is required. 11

12 SOLID FLOOR SYSTEM Polyplumb floor heating in solid or screeded floors incorporates the unique Polyplumb screeded floor panel. The light weight plastic floor panels nest for easy storage and carrying. The floor panels are easily cut to the room shape. They form a simple grid for the quickest possible pipe laying and form a precise guide for minimum bending radius. They set the pipe at exact centres and hold the pipe against movement when screeding. The floor panel holds the pipe above the insulation allowing full screed surround. Optimum screed depth is 65mm from panel base, i.e. 40mm from the pipe top. Insulation below and at the edges of the floor screed is required by Building Regulations. Edge insulation also acts as an expansion joint. * PRODUCT SELECTION PROCESS ROOM PACK Pipe at 100mm centres (100m Coils) HOUSE PACK Pipe at 200mm centres (80m Coils) unless otherwise stated Key Design and Installation Information Maximum heat output Recommended design flow temperatures Maximum circuit length Maximum coverage per circuit Material Requirements (approx) Approx. 100w/m 2 (see output table) 50 (see output table) 100m (15mm pipe) 120m (18mm pipe) 11 1m 2 at 300mm centres 21 2m 2 at 200mm centres 30m 2 at 300mm centres (18mm pipe) Pipe 8 2 m/m 2 at 100mm centres 4 5m/m 2 at 200mm centres 3 3m/m 2 at 300mm spacing (18mm pipe only) Floor plate usage 1 plate/m 2 allowing for cutting (Actual 1 2m 2 /plate) Edging insulation 1 1m/m 2 Conduit pipe 2m/circuit Note: Room Packs are supplied with pipe at 100mm centres (100m coils) and House Packs with pipe at 200mm centres (80m coils). *This product can be supplied as a pack see pages for more information Edge insulation strip Screed (minimum 65mm from Polyplumb screeded floor panel base, ie 40mm from pipe top) 65mm Polyplumb barrier pipe in screeded floor panel at 100mm or 200mm centres for 15mm system, 300mm spacings can also be used for 18mm systems Insulation board on damp proof membrane as required by Building Regulations Solid / structural sub-base Solid floor installation diagram 12

13 Edge insulation strips permit the free expansion of the floor screed The floor panels are laid above pre-installed insulation and are overlapped at the edges Floor panels being laid on top of pre-installed insulation Pre-installation requirements The sub floor must be swept clean and be free from mortar residues. Insulation Insulation should be laid in accordance with the requirements of Building Regulations. Edge insulation strips Edge insulation strips permit the free expansion of the floor screed and need to be installed around all surrounding walls and fixed constructions, such as columns, steps and access doorways. (installation pictured top middle). The edge insulation must also be used to separate areas where either the total area exceeds 40m 2 or lengths less than 8m exceed a length x width ratio of 1:2.5, eg corridors. Edge insulation is bent at 90º near to the base, to form a double-sided self-adhesive strip, which bonds the floor plates to the floor insulation. Edge insulation is laid in addition to perimeter insulation required by Building Regulations. Floor panels The floor panels are laid above pre-installed insulation and are overlapped at the edges. Note that the 1 /2 castellation overlaps the 3 /4 castellation; the first panel is therefore laid with the 1 /2 castellation edge nearest to the wall. The panel can either be cut using a saw or snips, or simply overlapped to the nearest fit. The floor panel should not be used at the base of the manifold, as pipes need to be closer together than the floor panels permit. Pipes around this area should be retained by pipe clips, which may also be used intermittently to secure the clip plate to the insulation. Pipe When the floor to be heated is covered by floor panels, pipe can be installed at the pre-designed centres. Unwrap the pipe from the coil completely and take pipe from the outside of the coil by unrolling the pipe in the direction that the pipe is being laid. Pipe laying The floor panel ensures that pipe is laid at the pre-determined spacing. 15mm pipe is laid at 100mm or 200mm centres as required; 18mm pipe may also be laid at 300mm centres. The minimum bend radius is ensured by encircling two castellations for a 90 bend or three castellations for a 180 bend (see diagrams below). 90º 180º 13

14 Pipe laying - Step one All circuits to be laid at 100mm and 200mm centres must be laid in a spiral configuration. The first loop of pipe should be laid around the perimeter of the area to be covered by that circuit. The next loop should be laid either 200mm from this pipe for spacing of 100mm, or 400mm from this pipe for spacing of 200mm. 3 * PRODUCT SELECTION PROCESS ROOM PACK Pipe at 100mm centres (100m Coils) HOUSE PACK Pipe at 200mm centres (80m Coils) unless otherwise stated *This product can be supplied as a pack see pages for more information 1 200mm for 100mm spacing 400mm for 200mm spacing Meander pattern Where 300mm spacing is required (18mm pipe systems only) a meander pattern can be used. The pipe simply crosses the room from one side to the other encapsulating three castellations at each return bend. Pipe laying - Step two Continue the loop of the pipe to the centre of the panels, leaving enough space to form a double return ( s shape in the centre of the loop). 2 Pipe laying - Step three Continue working out from the centre by filling the space between the two pipes on the primary circuit, therefore leaving pipes at the required spacing centres. Conduit pipe Conduit pipe should be used around heating pipe where the pipe passes through edge insulation strips, ie room, or through expansion joints within the floor. A section of conduit 400mm long Conduit pipe should be applied. Conduit is also used where the pipe leaves the floor adjacent to the manifold. This is normally threaded down the pipe after the pipework has been installed. Screed cover Screed should only be laid over the pipe that is pressurised to 6 bar, as this prevents pipes being crushed during the screeding process. Sand and cement screed should be laid to a depth of 65mm minimum (40mm cover over pipe minimum). Screed significantly greater than this thickness will delay initial heating times. 14

15 Timber - suitable for Polyplumb solid floor and suspended floor systems Although many people are concerned the effect of heat on a timber floor, much of this concern is misplaced. Of more importance is the floor moisture content. Timber floors should be laid at moisture content of 10% to 11%, which during the heating season will reduce to 8% to 9% and cause a very small amount of shrinkage. The floor will re-absorb some moisture when the heating is not operating and the moisture content will increase to 12% to 13% Application of Timber floors over Solid floor systems Where traditional oak flooring is to be laid on a solid floor, joists can be used at 1 metre spacings to provide a fixing point for the boards. Insulation, floor plate and pipe can then be laid between the joists and screed laid level with the top of the joists (see diagram). Individual circuits of pipe are laid between each set of joists and care should be taken to ensure that the screed is completely dry prior to the wood board covering being laid (see diagram). Timber floor covering Joist at 1 metre spacings Solid floor plate Screed Section Timber floor diagram Diagram 1 - floor plate between joists 15

16 SUSPENDED FLOOR SYSTEM Polyplumb floor central heating on suspended floors can be installed using a variety of methods. Pipe can be laid along the joists using double heat spreader plates or across joists on battens using single heat spreader plates. Pipe only systems can be used where heat outputs are less critical. Key Design and Installation Information Maximum heat output Approx. 70w/m 2 (see output table) Recommended design flow temp. 60 c (see output table) Maximum circuit length 80m (15mm pipe) 100m (18mm pipe) Maximum coverage per circuit 25m 2 at 300mm centres (15mm pipe) Single heat spreader plates 30m 2 at 300mm centres (18mm pipe) Maximum coverage per circuit 17m 2 at 225mm centres double heat spreader plates (15mm) Material Requirements (approx) Single heat spreader plates Double heat spreader plates (15mm and 18mm) (for 15mm pipe only) Pipe 3 1m/m 2 4 5m/m 2 Heat spreader plates 3 plates/m 2 2 plates/m 2 * PRODUCT SELECTION PROCESS All suspended floor house packs use double heat spreader plates AVAILABLE AS A HOUSE PACK *This product can be supplied as a pack see pages for more information Note: House Packs are only available with double heat spreader plates Tongue and groove flooring Double heat spreader plate (15mm pipe only) Polyplumb barrier pipe Polystyrene or foam insulation Supporting batten and joist Ceiling Suspended floor installation diagram 16

17 Joists at 450mm to 350mm centres using double heat spreader plates Joists at 300mm centres using double heat spreader plates Double heat spreader plates Installation and application using double heat spreader plates (spans of 450mm to 350mm) Where joist centres are 450mm to 350mm double heat spreader plates can be used to span the joists and support the pipe at 250mm centres (225mm average spacing). These plates run along the joists and are positioned to allow the return bends to cross joists through pre-prepared notches. 1000mm 250mm Dimensions of double heat spreader plate 450mm Double heat spreader plates Pipe Joists notched to accept pipe returns Suspended floor system: using double heat spreader plate 17

18 Single heat spreader plates Installation and application using single heat spreader plates (spans greater than 450mm or less than 350mm) Where it is not possible or desirable to drill or notch the floor joists, and the floor height can be raised, spreader plates can be used in the following way: 1) To prevent downward heat transmission, insulate between the voids in the joists with appropriate mineral wool or foam insulation. 2) Lay 75mm x 25mm battens across the existing joists at 300mm centres. Trim the ends of the batten back to the last joist at alternative ends. 3) Lay spreader plates between the battens and pin in position. Lay pipe into the spreader plates. Polyplumb barrier pipe Single heat spreader plates 75mm x 25mm battens at 300mm centres Joists at spacing greater than 450mm or less than 350mm Suspended floor system: using single heat spreader plate 1000mm 250mm Dimensions of single heat spreader plate 18

19 Pipe only systems The use of heat spreader plates is recommended, as they assist the response time and heat spread. However, in some circumstances, simply laying pipe in an air void between foil faced reflective insulation and the underside of the floorboard will be adequate. The space between the top of the insulation and the underside of the floor deck should be kept to a minimum (20mm) and care should be taken to ensure that the insulation is sealed at the edges and ends. The pipe only application would be suitable in areas where the heating response is less important, eg bedrooms, and is not recommended in living spaces or over unheated spaces, eg rooms above garages. I beam joists Where I beam joists are used plumbing and heating systems are installed from below through holes in the joist. Floor heating can be installed from below and insulation laid after the pipe is clipped in position. Installing floor heating from below through holes in the joists Installation using pipe only system Enhancing pipe only systems The effectiveness of pipe only systems can be enhanced by laying a weak (1:6) dry mix screed approximately 25mm thick between the joists. In order to apply this extra support may be required below the insulation. Although pipe only systems are designed at 60 C flow temperature, the flow temperature may be reduced when applying this detail. Before this system is applied it is suggested you consult a structural engineer to confirm suitability. Application of Timber floors over Suspended floor systems The application of timber flooring is possible on suspended floor heating systems only where the timber floor is laid directly over the under floor system. There should never be two layers of wood, i.e. chipboard overlaid with timber, as the resistance of the two layers would be too great for the heat passage. Tongue and groove flooring 25mm thick dry mix screed Joists Insulation Correct application Incorrect application Suspended floor installation with 25mm screed 19

20 FLOATING FLOOR Polyplumb floor heating is ideal for floating floors above existing timber or solid sub-bases. It incorporates the Polyplumb floating floor panel, which is a high density polystyrene insulation sheet with pre-formed pipe grooves at 300mm centres. Each panel includes pipe bending grooves. Key Design and Installation Information Maximum heat output Recommended design flow temperatures Maximum circuit length Maximum coverage per circuit Material Requirements (Approx) Approx 70w/m 2 (see output table) 60ºC (see output table) 80m (15mm pipe) 100m (18mm pipe) 25 8m 2 at 300mm centres (15mm pipe) 30m2 at 300mm centres (18mm pipe) Pipe 3 1m/m 2 at 300mm centres Floating floor panel 1 panel /1 4m 2 Single spreader plate 3 plates/m 2 * PRODUCT SELECTION PROCESS Floating floor systems are available as House Packs AVAILABLE AS A HOUSE PACK *This product can be supplied as a pack see pages for more information Tongue and groove flooring Polyplumb barrier pipe in single heat spreader plate Pre-formed Polyplumb floating floor insulation panel Damp proof membrane as required by Building Regulations Concrete or timber sub floor Floating floor installation diagram 20

21 Single heat spreader plates are laid in the pre-grooved insulation Pipe can be installed at the pre-designed centres of 300mm only Installation of floating floor panels Pre-installation requirements The sub floor must be swept clean and be free from mortar residues. Floating floor panel The 1200x1200x50mm floating floor panels are laid over the entire floor area to be heated, ensuring that the panel grooves are aligned. Panels can be cut to fit where necessary. A void in the insulation is often retained around the edge of rooms to allow for distribution pipes from the room to the manifold. Heat spreader plates Single heat spreader plates are then laid in the pre-grooved insulation. These plates ensure an even spread of heat across the floor area and clip the pipe firmly into the panel (pictured top middle). Pipe When the floor to be heated is covered by floor panels, pipe can be installed at the pre-designed centres of 300mm only (pictured top right). Pipe layout The maximum circuit length is 80 metres using 15mm pipe, or 100 metres using 18mm pipe. Pipe should be laid in the pattern shown opposite. Floor covering 18mm and 22mm tongue and groove floor boards can be laid over the under floor central heating system in the normal manner. Polyplumb barrier pipe Single heat spreader plates Insulated floating floor panel Floating floor system: using panels and single heat spreader plates 21

22 OVERLAY FLOOR SYSTEM Overlay is a perfect solution for a range of projects, including new build and renovation properties, single room refurbishments, floor areas served by a single manifold, or where wall space is limited or required for appliances. Overlay can be installed in most buildings and linked into the existing heating system via a zonal regulation unit (ZRU), or a stand alone system using an electric heat unit (EHU). The system uses a low profile panel that is laid over existing solid or timber floors. The 18mm thick panels are laid on the existing load bearing floor and glued together. The pre-formed plastic return bends are placed at opposite ends of the room. The 12mm barrier pipe is laid in the grooves, and the system can either be directly covered by tile or laminate flooring or a 4mm plywood capping layer used for vinyl. * PRODUCT SELECTION PROCESS Overlay is available in the following room packs - 5m 2 (Bathroom Packs), 12m 2 and 20m 2 AVAILABLE AS A ROOM PACK *This product can be supplied as a Key Design and Installation Information pack see pages for more information Maximum heat output Approx. 100w/m 2 Recommended design flow temperatures 45 to 50 C Maximum circuit length 75 metre Maximum coverage per circuit 12m 2 Material Requirements (Approx) Overlay floor panels Coverage 0 48m 2 Pipe 7metres/m 2 End returns 1 return bend per floor panel 12mm x 80 metre coil of pipe 1 coil per circuit 15mm x 12mm adaptors and stiffeners 1 pack per circuit Floor covering Polyplumb barrier pipe Overlay panel Overlay end return Concrete or timber sub floor Overlay installation diagram 22

23 Overlay is easily connected to existing heating systems Overlay can be fitted under any type of floor covering Pipe Installation with Overlay Design and planning Planning the Overlay system prior to installation will save precious time during the installation and maximise the use of the products. The direction of the pipe runs / panels, location of return bends and routing of pipes in rooms with multiple circuits should be planned prior to installation. Note that return bends have a removable panel, which allows for the provision of flow and return pipes to various circuits. Control apparatus (ZRU, EHU or manifold) must be positioned either in or adjacent to rooms to be heated. In some cases it will be necessary to use a router to create additional access to the panel grooves to ensure minimum cutting. Floor panels should be laid along the longest side of the room, similar to the process used in the laying of laminated or wooden floors. Example: Single room application Example: Multiple room application 23

24 Laying boards and end returns 1) Lay two end returns in the starting corner of the room 5mm from the wall, removing the panel for flow and return pipes as required by your plan shown below. 2) Clean dust and debris from all edges of the floor panel. 3) Apply a 3mm bead of adhesive to the first panel and glue to the end returns, ensuring that the glue does not flow into the grooves. 3 1 Return bends with pipe plate removed Apply a 3mm bead of adhesive to the end returns of the first panel First panel Room wall First row Subsequent row Return bends with pipe plate remaining 4) Line up panel and end return with grooves (Tip: use short lengths of 12mm pipe for alignment). 5) Staple to end return using 11-14mm staples at 150mm centres. 6) After the first row of panels is laid, stagger subsequent panels in a brickwork pattern. 7) When completed clear excess glue from grooves (use a section of 12mm pipe) and vacuum all debris from the floor. 8) You are now ready to lay pipe carefully into the floor plates. 4 Laying boards and end returns 2 Clean panels prior to applying adhesive Use a short length of pipe to help with panel alignment 24

25 Cutting the panels Panels can be cut using a hand saw or jig saw, preferably set at a slow speed. Cutting the panels generates dust and, therefore, panels should be cut either outdoors or in a ventilated room. Always use a particle mask when cutting. Finishing requirements Use a dry sand and cement mix to fill the void around the perimeter pipework. Floor coverings Tiles and wood laminate can be laid directly over the Overlay system. If tiling, use a flexible adhesive and grout. If using carpet or vinyl, lay 4mm plywood over the panel and staple to the panel. Note: Mark pipe locations to avoid stapling. Fill gaps with sand and cement mix where required Circuit 1 Circuit 2 Router panels to enter and exit circuit Schematic layout: Conservatories Circuit 1 Router panels to enter and exit circuit Cut panels using a panel saw, on a low speed setting Laying pipe The 12mm barrier pipe has an interference fit into the panels and, therefore, a tap with a soft headed mallet may be required. Pipes should be laid in an up and down pattern, taking the pipe out to the furthest point away from the control apparatus and working back to ensure even heat spread. Pipe connections Use the 15x12mm push fit adaptors and pipe stiffeners to connect the pipes to standard 15mm connections (eg manifold, zonal regulation unit or electric heat unit). Circuit 2 Schematic layout: L-shaped rooms 25

26 MANIFOLDS Manifolds are common to all systems above 25m 2, independent of the floor application. Manifolds are supplied complete and positioned on a bracket. They can either be fixed directly to a wall or positioned in a manifold box. The manifold comes complete with a drain and air vent assembly, which can be positioned on either end of the manifold. Isolation valves are supplied separately for the supply end of each manifold. The bottom manifold is the flow and the top manifold is the return. Each manifold port comes complete with a Polyplumb push fit connection. Pipes are connected to manifolds by inserting a pipe stiffener into the pipe and following the instructions on pages The flow meter on each flow port of the manifold provides a visual indication of the flow through each circuit. Both manual and lockshield balancing can be undertaken by either using the blue cap on the return manifold for manual adjustment, or removing the blue cap and adjusting using the key supplied with each manifold. Preparing and installing the manifold Remove the manifold from the box and arrange the flow and return manifolds to ensure that the inlets/outlets are pointing downwards. Remove the air vent and drain valve from the packaging and connect to the desired end of the manifold. Ensure the seal is correctly in place before tightening the compression nut by hand on to the manifold. To ensure the valves are securely connected to the manifold, use a 38mm spanner or wrench to tighten by a further half turn. Remove the isolating valves (supplied separately) from the packaging and connect to the opposite end of the manifold. As with the air vent and drain valve, ensure the seal is correctly in place before tightening the compression nut by hand on to the manifold. Then, as previously, complete the connection by using a 38mm spanner or wrench to tighten by a further half turn. Fix the manifold horizontally in the desired position utilising both screw holes on each bracket. The manifold is now in position and ready to be connected to the mains from the boiler and the floor heating circuits. A set of self adhesive stickers are included to help identify each circuit on the manifold. The stickers also provide the opportunity to record the number of turns required for the correct flow rate through each circuit (for further information see testing and commissioning on pages 34-35). Flow setting and adjustment As with any type of wet heating system, it is a necessity to pressure test a floor heating system to check the integrity of all the joints. To set the flow rate of the circuit remove the protective blue cap from the manifold port. Using the key, turn the spindle clockwise until the manifold port valve is fully closed. Adjust the flow of the port by turning the spindle anti-clockwise. Three full turns of the spindle will open the valve fully. Flow through the valve can be measured by the flow meter on the flow ports of the manifold. Once each manifold port has been set to the correct flow rate the protective blue cap can be refitted. Alternatively, if zone control is being utilised actuators can be fitted to the relevant ports. 1" Height Return 50 Supply Manifold length see below 210 1" Ports Length (mm) 26

27 WATER TEMPERATURE CONTROLS The temperature of water required in floor heating systems is less than that required for radiators or stored hot water. If these other services are connected to the same boiler it will be necessary to control the water temperature using one of the Polyplumb water temperature control units. * PRODUCT SELECTION PROCESS The UFCH control pack is included when selecting House Packs *This product can be supplied as a pack see pages for more information Modulating pump unit (PB970014) The modulating pump unit controls water temperatures between 45 C and 60 C. The inclusion of a modulating pump ensures that the flow to the floor heating circuits is automatically adjusted to allow for the opening and closing of actuators when individual room temperature is required. The unit is suitable for manifolds demanding up to 15Kw heat load. The temperature of the water is set using the pilot pin on the hand wheel. When the pilot pin is flush with the hand wheel the temperature is set to 55 C. Each click to + or increases or decreases the temperature by 1 C. The modulating pump unit is fitted directly to the manifold at either end by turning the pump through 180. An additional zone valve is required when using the modulating pump unit supplied by others. Floor heating control pack (PB970015) The pack controls water temperatures between 35 C and 60 C, and incorporates a fixed head pump and a 22mm 2-port zone valve, which is suitable for manifolds demanding up to 15Kw heat load. The set temperature of the water is shown on the wheel head. The control pack is fitted directly to the manifold at either end, as both left hand and right hand connector bends are supplied with the unit. UFCH control pack 30mm 130mm 40mm 110mm 155mm 50mm Dimensions of assembled unit Note: The valves shown on this diagram are purchased separately and not supplied with the unit. Manifold bends (PB12735) 290 mm The water temperature control packs can be fitted at 90 to the manifold using the manifold bends. This allows manifolds and pump units to be corner mounted where space is at a premium, eg understairs cupboard. 260mm Pilot pin flush to handwheel a) b) Modulating pump unit a) Manifold bend installed with modulating pump unit b) Manifold bend installed with floor heating control pack 27

28 ROOM TEMPERATURE CONTROL A comprehensive range of room temperature control products compliments Polyplumb floor heating systems. The control packs below are designed specifically for floor heating, which is controlled differently to radiator systems. Controlling floor heating The control of floor heating systems is different to that of conventional radiator systems, as the space should not be allowed to cool completely during the heating season. The temperature during unoccupied or night time periods should fall to around 4 C lower than the occupied temperature. This lower temperature setting is known as the set-back temperature, eg occupied temperature 21 C, set-back temperature 17 C. Individual room control Polyplumb floor heating controls allow each room to be individually controlled, through programmable room thermostats and a master wiring centre, that when connected to valve actuators (PB00401) allow each room to have individual time and temperature settings. As the desired room temperatures are achieved, the actuators to those circuits will close. When all rooms on a manifold are satisfied the manifold pump will stop, the zone valve will close and the signal to the boiler will be cut. As all individual rooms are heated only when they are required the system ensures maximum comfort and system efficiency. 4 Zone Master and 4 Zone slave unit The number of control zones you require will depend on the number of rooms you wish to control individually. The 4, 6 and 8 zone packs describe the number of areas you wish to control, not necessarily the number of circuits you are supplying from that manifold. To optimise the use of each control pack you will need to understand the following guidelines: The 4 zone pack contains 4 room thermostats, the 6 zone pack contains 6 room thermostats and the 8 zone pack contains 8 room thermostats. Each room thermostat can control 1 zone and up to 4 actuators. Rooms over 40m 2 should be allocated as 2 zones and have 2 room thermostats. An actuator is required on each circuit that requires control. Circuits serving small areas, WC s, cloakrooms, dressing rooms etc, can be installed as subservient rooms, ie controlled by a room thermostat in the master room, eg hall and WC, bedroom and dressing room. Programmable room thermostat 28

29 Control equipment The 4 zone master unit provides wiring connections for the boiler (including volt free), zone valve, UFH pump, and up to 4 programmable room thermostats (control zones) and actuators (maximum 4 per zone). A 4 zone master unit is required at each manifold. The 4 zone slave unit simply plugs into the master unit and provides additional connections where more than 4 programmable room thermostats (zones) are required. Wiring connections for an additional 4 programmable room thermostats (zones) and subsequent actuators are provided. Programmable room thermostats (PBPRP) The programmable room thermostat provides time and temperature control in each zone. Features include: 7 day programmer Set-back temperature setting Frost protection programme Holiday programme 5 pre-set programmes for easy set up No loss of programming when battery change required Can be connected to wet room sensor (PB23020) Wet room sensor (PB23020) Where time and temperature control needs to be applied to a bathroom or wet area, the wet area sensor can be installed within the wet room and connected to the programmable room thermostat installed in an adjacent dry area. The sensor is supplied with 3m of cable and can either remain in the supplied housing and be wall mounted, or removed from the housing and used as a floor surface sensor. Wet room sensor The Packs available and content of each is as follows: Pack Single Zone 4 Zone 6 Zone 8 Zone Pack Code PB1ZP PB4ZP PB6ZP PB8ZP Content 4 Zone Master Zone Slave 1 1 Programmable Room Stat Manifold 1 - A 4 zone pack would be required with 8 actuators Room Number of Room temperature Room Actuators Wet room circuits control required thermostats sensors Lounge 3 Yes Dining 2 Yes Kitchen 1 Yes Hall 1 Yes WC 1 Off hall thermostat TOTAL Manifold 2 - An 6 zone pack would be required with 8 actuators & 3 wet room sensors Room Number of Room temperature Room Actuators Wet room circuits control required thermostats sensors Bedroom 1 2 Yes Bedroom 2 1 Yes Bedroom 3 1 Yes Bedroom 4 1 Yes Bathroom 1 Yes En suite 1 1 Yes En suite 2 1 Yes TOTAL Examples (1 & 2): Material scheduling for typical four bed property * PRODUCT SELECTION PROCESS House Packs include the programmable control packs are also supplied with 1 wet room sensor (4 zone & 6 zone) or 2 wet room sensors (8 zone) *This product can be supplied as a pack see pages for more information 29

30 CONNECTING TO HEATING SYSTEM Polyplumb floor heating systems can be installed with minimal disruption to existing heating and electrical supplies. They are compatible with standard central heating boilers, and are particularly suited to achieving maximum economy from a condensing boiler or heat pump. Direct connection Floor heating systems are normally connected directly to the primary boiler pipework. It is recommended that a zone valve be installed on the pipe flow prior to each manifold. When connecting the floor heating directly to the main heating primary pipework, it is important to ensure that the boiler is compatible with secondary pumps, ie floor heating pumps. You should also ensure that them recommended flow rate through the boiler is compatible with the flow requirement of the floor heating system. Indirect connection Where several manifolds are used on large installations, installers may consider indirect connection to the boiler through a thermal store. The use of a thermal store ensures that the demands of the floor heating do not directly affect the hydraulics of the boiler or the primary pipework. As a large volume of water is stored at high temperature, this reduces the number of firing sequences of the boiler. It is recommended that a zone valve be installed on the flow pipe prior to each manifold. Connection to hot water /radiators/additional UFH manifold Primary heating pump Connection to water temperature control unit and UFH manifold Valved by-pass boiler Diagram of direct connection Connection to radiators or additional UFH manifold Primary heating pump Connection to water temperature control unit and UFH manifold Valved by-pass boiler Diagram of indirect connection 30

31 HEAT OUTPUT TABLES Solid Floor Heat Output 15mm and 18mm pipe Room Temperature Pipe Spacing (mm) Flow Temp ( C) Output (W/m sq) Floor Temp ( C) 18 ºC (18mm pipe only) ºC (18mm pipe only) ºC (18mm pipe only) Suspended and Floating Floor Heat Output 15mm and 18mm pipe Room Temperature Pipe Spacing (mm) Flow Temp ( C) Output (W/m sq) Floor Temp ( C) 18 ºC ºC ºC

32 JOINTING AND DE-MOUNTING Polyplumb manifolds use Polyplumb fittings for connecting to a circuit. As many of our domestic floor heating systems use 15mm Polyplumb pipe, any of the pipe not required for your project can be re-used for other heating or hot/cold water services using the Polyplumb fittings range. Jointing There are six stages to successfully jointing the Polyplumb system. These instructions apply to Polyplumb when used in hot and cold water or heating applications, including floor heating. 1(a) Cutting Polyplumb pipe Always use one of the approved pipe cutters (PB777 or PB778). A slight rotation of the pipe when cutting will help make the operation easier. Never use a hacksaw. Wherever possible, cut on a depth insertion mark. These K shaped marks are equally spaced along the pipe and indicate the depth required for full insertion into a Polyplumb socket fitting. 1(a) Cutting Polyplumb pipe 1(b). Cutting copper pipe for insertion into a Polyplumb fitting Wherever possible, use a rotational pipe cutter when cutting copper pipe. Ensure that all cut ends have a rounded lead in, with burrs removed. Never use a hacksaw. You will need to mark the depth insertion on the pipe, the insertion depths are shown in the table below. Pipe diameter (mm) Insertion depth (mm) 2 Use of pipe stiffener 2. Use of pipe stiffener Pipe stiffeners are an integral part of the joint when using Polyplumb pipe with either Polyplumb fittings or compression fittings, and need to be fully inserted in to the pipe end. They are not required when using copper pipe. 3. Visual check of fitting & fitting components Although every single socket is visually checked during the manufacturing process to ensure that all components are present and in the correct order, a further visual check is recommended as tampering by others can take place on site or during distribution. The cap should be hand tight only. Caution - Do not insert fingers into the Polyplumb fittings, as the grab ring is sharp and designed to grip. Note: Components shown in de-jointing section. 4. Insert pipe fully into fitting The pipe should be inserted into the fitting to full socket depth, such that the insertion depth mark aligns with the outer end of the cap nut on the fitting. 5. Grab ring check A quick tug on the pipe will confirm that the pipe is inserted past the grab ring and that a grab ring was present in the fitting. It does not, however, ensure that the pipe is fully inserted, as this can only be confirmed by using the depth insertion mark. 32

33 Retaining Cap cap Spacer washer (28mm only) o ring Grab ring Pipe stiffener Spacer Spacer washer 6. Avoidance of re-jointing - WARNING! On no account should a pipe be removed from a jointed Polyplumb fitting by removing the cap-nut and withdrawing the pipe end, complete with all the socket components, from the fitting to be re-jointed without removing and replacing the grab-ring into the fitting and re-making the joint in accordance with the normal Polyplumb jointing procedure. If the pipe end, complete with all the socket components, is subsequently re-jointed into the body of a fitting, there is a risk that the outer edge of the grab-ring could catch on the outer end or the inside surface of the socket of the fitting, which forces the grab-ring into an angled position on the pipe. Forcing the grab-ring into an angled position on the pipe in this way seriously damages the grab-ring teeth and will reduce the pull-out performance of the joint when subjected to pressure, such that premature failure will almost certainly occur. De-Mounting Polyplumb fittings must not be dismantled for any reason prior to jointing. Using the spare component pack: 1. If it is necessary to remove a jointed pipe from a fitting, the cap-nut should be unscrewed and the pipe, with all the socket components present on the pipe end, should be pulled out of the socket of the fitting. The pipe end, complete with all the socket components, should be cut off and discarded. A complete component pack of socket spares should be fitted to the socket, as described in the following paragraph, and pipe jointing should be carried out as described on page The component pack (PB95**) is supplied as a cap-nut, with all the socket components present in the correct order, and retained by a clip-on protection cap. 3. Remove the protection cap, ensuring that the socket components remain within the cap-nut. 4. Without removing any of the socket components from the cap-nut, introduce the cap-nut and socket components to the socket of the fitting and tighten up the cap-nut by hand, ensuring that the components enter the socket without snagging. 5. Carry out a visual check to ensure that all socket components are present in the correct order, as shown in the diagram, and that the rubber O -ring is lubricated. If in doubt, the O -ring should be re-lubricated using Polyplumb silicone lubricant. 6. Carry out pipe jointing as described on page 31. **Represents different sizes 33

34 FLOOR HEATING COMMISSIONING PROCEDURE Once installed, Polyplumb floor heating systems should be tested thoroughly to ensure they are working effectively, including initial filling of the system and system balancing. If you require any further information please contact the Polypipe Technical Team. Initial filling of system: 1. Close manifold isolating valves. 2. Connect a hose pipe to the manifold flow port via the drain off/filling point on the manifold. The other end of the hose should be connected to a mains cold water supply. 3. Connect a second hose to the return manifold and take it to a suitable discharge point such a drain or back inlet gully. 4. Open one of the blue decorator s caps on top of the manifold and commence filling the system via the mains cold water supply. Once the water is running smoothly through the circuit and all of the air has been expelled, open the second blue cap and close the first. Repeat this process until all of the circuits have been filled and the system is free of air. Close the drain/filling points and remove the hoses. 5. Connect a suitable pressure test pump to the flow manifold filling point and test the system to 6 Bar. Leave system under pressure for one hour to confirm the integrity of the installation. Once the pressure test is complete reduce the system pressure down to 3 Bar whilst the screed is applied. Important note: Do not leave system under pressure during cold weather when there is a risk of freezing. 1" Height Return 50 Supply Manifold length see below 1" System balancing: Once the system is up and running it will be necessary to balance the system in accordance with the design data as provided. This should be done using the following method. 1. Open the manifold isolating valves. Ensure that the boiler is operating correctly and that the correct temperature water is being provided at the manifold mixing valve. Please note that due to the design of the mixing valve it is necessary to provide water from the boiler at least 15ºC hotter that the required underfloor heating operating temperature. For example; if the underfloor heating system has been designed to operate at a flow temperature of 50ºC, the boiler should be able to provide a primary flow temperature to the manifold mixing valve of 65ºC min. (Please note that for systems connected to a heat pump installation different criteria may apply. Please contact Polypipe Technical Support for further information.) Adjust the mixing valve temperature setting accordingly to match the precise manifold design requirement using the dial thermometers as supplied. 2. Ensure that the underfloor heating circulating pump is set to a suitable fixed head speed using the pump adjustment facility. This is particularly important for systems fitted with modulating pumps. Remove the blue caps from the manifold return rail (or actuators if already fitted) and using the radiator key supplied adjust the circuit/s to each room in accordance with the Polypipe design data. This is done by fitting the radiator key over the square fitting that protrudes from the top of the valve body. By turning the key clockwise the flow rate is decreased. To increase flow rate turn the key anticlockwise. Adjust each circuit until the flow meter on the manifold flow rail reads the required flow rate. Repeat the procedure for all circuits connected to the manifold. If a modulating pump is fitted return the pump to its modulating operation mode. 3. Refit the manifold actuators and check their correct operation to each circuit by operating the appropriate room thermostats. 34

35 Pressure testing in sub zero temperatures Special precautions are necessary if the pressure testing is to take place in sub-zero temperatures. This applies particularly when using the screeded floor heating system, where most of the pipe is encased in screed. Due to the contact between pipe and floor panel on screeded installations, where the screed does not completely surround the pipe, there may be points where strain is created on the pipe in freezing conditions, which is not normally present. Therefore, it is advisable to drain the floor heating system once testing and screeding has been completed. System chlorination Short term chlorination for disinfection of supply pipework and normal levels of chlorine in UK domestic water supplies will not have an adverse effect on Polyplumb. Polyplumb is not suitable, however, for systems that carry a high concentration of chlorine, ie supplies to swimming pools, etc. Tips: If there is an excessive amount of air present the system will be noisy and the flow meters may appear to bounce up and down. If this happens, repeat the initial filling procedure until the system is fully purged of air. If the system has been left standing for a long period of time or if contaminants are present in the system water, the flow meters may appear discoloured or cease to work. If this is the case, turn off the manifold isolating valves and remove the manifold flow meter/s. Using a soft brush, gently wash under a tap until all of the debris has been removed. Check the manifold opening for any signs of contamination and flush the system if necessary. Refit manifold flow meters. Should the damage to the flow meter/s be too great it/they should be replaced. If the original system design data has been lost or is unavailable it is possible to adjust the manifold flow rates using the simple rule of thumb method as described below: As the maximum length of any single Polypipe underfloor heating circuit should not exceed 100m, we know that when installed in to a solid floor system using 100mm pipe spacings and allowing for minimum connection lengths, it is possible to cover approximately 10m 2 of floor area. Given the maximum heat output achieveable from this type of system (100 watts per m 2 ) we therefore know that a 10m 2 area of floor can give out approximately 1kW of heat. In order to meet this requirement a flow rate setting of approximately 1.5 litres per minute will be required. Typical average flow rates assuming a 10ºC temperature drop across the manifold: 50 watts per m 2 = Flow rate setting 0.7 l/pm 75 watts per m 2 = Flow rate setting 1.0 l/pm 100 watts per m 2 = Flow rate setting 1.5 l/pm 35

36 PRODUCT SELECTION PROCESS In order to make ordering materials for either single room projects or whole floor areas simpler and easier, the product selection process allows customers to select the pack of their choice in three easy steps. You simply decide whether the project is a single room, a whole house solution, or requires a bespoke design. Then complete each of the three steps and order the resulting pack. It couldn t be easier. All packs have a single order code and include the necessary flooring materials, pipe, distribution (manifolds, ZRU, etc), water temperature and room temperature controls. To select the appropriate solution, choose from the following options: Design services For projects that fall outside the scope of the Room Packs or House Packs, Polypipe offers a fully bespoke design and component service. To utilise this facility, simply complete the enquiry form on page 43 or at and submit your drawings to Polypipe. You will then receive a complete design and component list for the project. Room packs The Room Packs are designed for single room applications: ie kitchens, bathrooms, conservatories, loft conversions and extensions. This range of floor heating packs contain all the flooring and control equipment required for a single project, in both solid floor and Overlay options. House packs The Polyplumb House Packs provide installers with a quick and easy way to select and order from our range of underfloor heating products, without the need to submit a design. The packs are designed for solid, floating or suspended (Double Heat Spreader Plate) projects. The packs can be applied to all new build or renovation properties that fall into the following criteria: Rooms requiring up to 70w/m 2 Properties built to current Building Regulations Projects where the manifold can be positioned within 6m of the room entrance 36

37 SELECTION CRITERIA - ROOM PACKS If you are installing floor heating in a single room, then the Polypipe Room Packs are a quick and easy solution. They include all the floor heating and control products you require, and come in a range of sizes to cover areas from 5m 2 20m 2. The Room Packs are suitable for either solid floor or Overlay systems. Please note that all Room Packs have a maximum output of 100w/m 2. Selection criteria for Room Packs: So Solid Floor Floor type Solid Floor (Code So) Overlay (Code O) Example: The order code for a solid floor with a floor area of 12m 2 would be: Control type For other floor types and areas, please refer to pages ZRU (Code Z) For connecting to existing heating. The Zonal Regulation Unit or ZRU connects to pipework in an existing heating system and converts this supply to a flow rate and temperature required for under floor heating. Sensors within the unit ensure that operation only occurs when heat is available from the existing heating meaning that no wiring is required, this means that wiring is not required between the ZRU and existing heating. Water is thermostatically blended to provide an ideal temperature for under floor heating and space temperature can be regulated by means of a room thermostat. Manifolds are not required, as if two circuits are required these can simply be connected using Polyplumb tees. Note: The Polyplumb ZRU will only operate when the water temperature in the under floor central heating system is sufficient to maintain pump operation (on 45 C, off 37 C). Floor area Select the total heated floor area and round up to the following options: Solid Floor Pipe thermostat 200mm Thermostatic blending valve Code Code 12m m 2 20 Overlay Code Code Code 5m m m mm Pump Heating return Pump speed control Example: The order code for a solid floor with a floor area of 12m 2 would be: So 12 Heating flow Tees and spigot elbows for second circuit if required Under floor heating flow Under floor heating return Solid Floor 12m 2 Floor Area ZRU 37

38 ON PUMP OFF PUMP ON OFF TIMER Control type continued The EHU is a 2Kw electric boiler which is an ideal solution for areas of up to 12m 2 where it is either difficult to connect to existing wet heating services or it is required to operate the area independently of the existing system. Manifolds are not required, as where two circuits are required these can simply be connected using Polyplumb tees. A 13-amp power supply is required. The Polyplumb EHU comprises of the following components: 2Kw Heater 15 Kpa Pump 2 litre Expansion Tank Isolation Valves Hanging Rail Temperature Setting Neon Display Integrated Time Clock Example: The total order code for a solid floor with a floor area of 12m 2 and a ZRU would be: So 12 Z Room Packs Packs Codes Overlay Single Room Packs 05B 012Z 012E 020Z Product Qty Qty Qty Qty Overlay Temperature Limiting Valve 1 Overlay Panels (Pack of 10) 1 1 Overlay Panels (Pack of 30) Overlay Glue Overlay End Returns (Pack of 10) Overlay Pipe 12mm x 80m x 15mm Adaptors (Pack of 2) ZRU 1 1 EHU 1 Room Packs Packs Codes Solid Floor Single Room Packs So12Z So12E So20Z Product Qty Qty Qty Solid Floor Panels Edge Insulation mm x 100m Pipe Coil Pipe Stiffeners ZRU 1 1 EHU 1 Floor Type Area M2 Control type Code Solid 12 ZRU So12Z Solid 12 EHU So12E Solid 20 ZRU So20Z Overlay (Bathroom) 5 Temp Limit Valve* O5B Overlay 12 ZRU O12Z Overlay 12 EHU O12E Overlay 20 ZRU O20Z Solid Floor 12m 2 Floor Area ZRU 250mm Feed and expansion tank with sight glass Unit isolation valves 570mm Heater unit Electrical connection box System isolation valves and filling point Pump and timer EHU 38

39 HOUSE PACKS Polyplumb House Packs are suitable for the majority of properties. However, before specifying you should ensure that your project is compatible by calculating the heat losses and correct manifold position. Heat losses Polyplumb House Packs are suitable for the majority of new build domestic properties built to current Building Regulations, as the heat output from these systems is 70 w/m 2. Use the chart below to check the compatibility of the space to be heated: Floor Area Rooms with Rooms with Rooms with 1 air change / 1.5 air changes / 2 air changes / hour (typically hour (typically hour (typically bedrooms) living areas) bathrooms & kitchens) One Two One Two One Two Outside Outside Outside Outside Outside Outside Wall Walls Wall Walls Wall Walls m 2 w/m 2 w/m 2 w/m 2 w/m 2 w/m 2 w/m Please remember: 1 pack is required per floor level or manifold 1 pack is required per floor type ( e.g. solid, floating etc) The maximum floor area per pack is 100m 2 The maximum number of circuits per manifold is 12 House Packs Selector Guide Using the quick selector guide below to determine how many circuits and control zones you will require for your floor area. Before specifying Polyplumb House Packs you should ensure that your project is compatible by calculating the heat losses and correct manifold position. Rooms heated satisfactorily with UFH Rooms where additional heating may be required The heat losses (above) are based on the following: Internal design temperature: 21 C External design temperature: 3 C Outside Walls: U = 0.35w/m 2 C Window area: 20% of Floor area U=2.2w/m 2 C Ceiling: U = 0.25w/m 2 C Manifold position Each manifold must be located within 6m of the room entrance (12m total flow and return length). If you require more than one manifold to achieve this you will require one pack per manifold. Choice 1 - Floor Area Choice 2 - Number of Circuits Circuits Floor Area m ,4 1, ,4 1,4 1,4,6 50 1,4 1,4 1,4,6 1,4, ,6 4,6,8 4,6,8 70 4,6 4,6 4,6,8 4,6,8 4,6,8 4,6,8 80 4,6 4,6,8 4,6,8 4,6,8 4,6,8 90 4,6,8 4,6,8 4,6,8 4,6,8 4,6, ,6,8 4,6,8 4,6,8 4,6,8 4,6,8 4,6,8 Choice 3 - Number of Control Zones 6m max Manifold 39

40 HOUSE PACK SELECTION The House Packs are suitable for solid, floating or suspended systems. Please note that all House Packs have a maximum output of 70w/m 2. Selection criteria for House Packs, once you have assessed compatibility: Floor type and area Select the floor type applicable for each area served by a single manifold from the following options: Solid floor (Code So) Floating floor (Code F) Suspended floor (Code D) Select the total heated floor area served by the manifold.this area should not include the areas taken by internal walls or stairs. Example: Room 1 = 28m 2 Room 2 = 20m 2 Room 3 = 12m 2 Room 4 = 5m 2 Total Floor area = 65m 2 7m Room 1 4m 1m 4m Room 3 5m Room 2 5m 4m 3m Room 4 The order code for this floor area with a solid floor would be: So 70 6 Solid Floor 70m 2 Floor Area 6 Circuits 7m Room 1 1m 4m Room 3 4m 3m 5m Room 4 Room 2 Temperature Control Zones Usually one per room should be sufficient. However, some rooms may be subservient to adjacent rooms: e.g. WC controlled off hall thermostat, or dressing room controlled by bedroom. Example: The total number of Control Zones is 4. 4m 5m The order code for this floor area with a solid floor would be: So 70 Solid Floor 70m 2 Floor Area Select the number of circuits required Each circuit cover 15m 2 so rooms greater than this will require a circuit for every 15m 2. All solid floor circuits at 200mm centres. Example: Room 1 = 28m 2 = 2 circuits Room 2 = 20m 2 = 2 circuits Room 3 = 12m 2 = 1 circuits Room 4 = 5m 2 = 1 circuits Total circuits required = 6 Room 1 So Solid Floor 70m 2 Floor Area 6 Circuits Room 1 4 Control Zones Room 2 Room 4 The order code for this floor area with a solid floor would be: 40

41 FLOOR HEATING - PRODUCT SELECTOR Selecting the right Polyplumb Floor Heating Pack couldn t be easier. Simply decide whether the project is: (a) a single room (b) a whole house solution (c) requires our design Complete each of the 3 steps for your chosen project Order the resulting pack number or submit your design request to Polypipe ROOM PACK 5m 2 Overlay Pack - including temperature limiting valve: Code: 05B FLOOR TYPE SOLID OVERLAY So O ROOM AREA 12m 2 / 20m 2 L x W When the Room Pack section is complete, transfer your code into the box below: CONTROL UNIT ZRU Z: 12m m 2 EHU E: 12m 2 only HOUSE PACK Selection for each manifold and each floor type - Max area for each manifold House Pack/Room Name Area (m 2 ) No of Circuits 1 / 15m 2 / Room Control Required (Yes/No) Room 1 Room 2 Room 3 Room 4 Room 5 Room 6 Room 7 Room 8 Total area (add total room area) Total No of Circuits Total control zones 41

42 DESIGN SERVICE For projects that fall outside the scope of the Room Packs or House Packs, Polypipe offers a fully bespoke design and component service. To utilise this facility, simply complete the enquiry form and submit your drawings to Polypipe. You will then receive a complete design and component list for the project. Our comprehensive design service includes: System design, including heat loss calculations for residential applications Circuit lengths Circuit pressure losses and velocities Flow rate settings per circuit Full product material specification Schematic circuit layouts (not full working drawings) Installation Service pre-project training at training centre pre-project training by distance learning on-site assistance if required during project installation Back up Service technical representation available to discuss systems in general and particular projects web-site and information on CD specialist technical hotline on